BEUMER Group: Using a modular system to provide customised intralogistics solutions:

"Customers want a process, not a system"

In the field of intralogistics, the trend towards automation is continuing

at full pace. In order to increase their competitiveness, companies want

their plants and systems to work more efficiently and safely. At the same

time, workplaces are required to be designed more ergonomically.

Additionally, the emergence of Industry 4.0 integrates all of the involved

people, systems, machines and products into one dynamic network. This

allows customers to better organise and manage their logistics value

chain. BEUMER Group leverages a modular standardisation concept to offer

customised solutions for individual tasks.

"Intralogistics is experiencing a transformation due to demographic

changes and also because of increased process complexity. Automation

technology in particular is constantly pushed forward," recognises

Franz-Joseph Kleigrewe, Head of Automation at BEUMER Group. This way

manual processes can be optimised and effective synergies formed between

man and machine. "Automation technology is the key to technical

development and progress," Kleigrewe is convinced.

There are three equally important factors involved in the development

process of automated systems: Customer orientation, innovation and

standardisation. If the focus is customer-oriented, the result are

typically tailor-made solutions that can rarely be used for other

projects. Focusing on innovation offers both opportunities and risks:

innovation creates competitive advantages, but also poses the risk of

increasing costs and postponing deadlines. One thing is clear: without

innovative projects, there is no progress. Forward progress is why these

projects need to be done regularly, while being aware of the potential

risks. The procedure for standardised solutions is very different. They

have been tried and tested. The customer receives an inexpensive and

functionally reliable system, which can go live in a short period of time.

Standardised, yet tailor-made

This can be a challenge. The customers' requirements can be very specific.

Each industry is different: from non-metallic mineral processing to

chemical and mining industries, from CEP services to airports. National

regulations and factory standards differ as well. At BEUMER Group,

customised machines and systems are therefore created from the modular

system: the mechatronics modules for mechanics, electrics and software are

adapted to the customer's requirements.

"Operators no longer wish to run just one machine, they want a process: a

combination of several coordinated systems," Kleigrewe recognises as the

market need. This includes filling, packaging and palletising solutions:

BEUMER Group offers the BEUMER fillpac, a filling machine particularly for

the building materials industry. Users can flexibly integrate and adapt it

to existing packaging lines. Depending on project requirements, BEUMER

Group offers varying designs. "We can provide this filling system with

special weighing electronics, for example, coming from the modular

system," Kleigrewe explains. It ensures the weight accuracy of the bags.

Depending on the application, BEUMER Group provides the system as a rotary

or inline filling machine, with bag discharge line, bag placer, different

number of filling spouts or devices for material feed and spillage

transport. As a systems supplier, the company offers the BEUMER paletpac

and BEUMER robotpac construction series, two different palletising

solutions that guarantee efficient stacking of filled bags. They can be

provided with functionalities such as bag and empty pallet transport

systems, from the modular system. Depending on the product

characteristics, the BEUMER paletpac is equipped with either bar-type,

clamp-type or twin-belt turning devices. They turn the bags rapidly and

gently to the required position. The high-capacity packaging system,

BEUMER stretch hood, is BEUMER Group's efficient solution to package the

pallet stacks quickly and safely. The system provider offers them in

different designs, with a varying set of sophisticated features.

Sortation and distribution - customised

Whether mail or parcel service providers, airports or food industries -

the requirements of sortation and distribution technologies vary widely.

Especially for mail and parcel service providers, the material handling

technology in distribution centres becomes increasingly complex. Sortation

and distribution systems must be able to handle increasingly complex tasks

and often adapt to different local conditions. Highly efficient processes

are necessary to ensure quick delivery of packages to the customer. Some

of the reasons are the changing consumer habits and trends, such as the

growth of e-commerce. BEUMER Group offers different solutions including

cross belts, Tilt Tray and E-Tray sorters. Depending on the application,

these systems can be provided with modules and functionalities from the

module unit, such as scanners, feeding posts, different induction units

and discharge systems, balances or DWS systems.

Software from the modular unit

BEUMER Group has developed the modular BG software suite, offering users

optimum and continuous control of their material flows. It can be

customised to the user's requirements. Products from other companies can

easily be integrated. Its name, BG, stands for BEUMER Group and the

software suite is a superior data processing system. Users can extend this

modular solution at any time and optimise their material flows. Process

data or reports are displayed on the BG Fusion user interface that works

for all programs. Users can access all available data, without having to

switch between the applications. They can also use the BG software suite

on mobile devices, such as tablets.

The BEUMER Group Warehouse Control System (BG WCS) module allows you to

connect the BG software suite to the warehouse management system or the

ERP system of the customer via a network connection. This way, BEUMER

Group ensures the communication between the different control levels for

the user. As a single-source provider, BEUMER Group can create an

intelligent connection between the individual systems, and integrate them

into existing process and inventory control systems. The customer receives

everything from one single source. The risk for error sources that could

result from interfaces is avoided. Technicians carry out the electrical

installations, as well as the integration of the machine and system

controls. "We also offer support during commissioning," says Kleigrewe.

Customer-focused engineering

"The equipment and systems for our customers fulfil the required

functions," says Kleigrewe. "But we also observe our customer's

standards." One of the customers is an international manufacturer of

petrochemical products. As a single-source provider of filling,

palletising and packaging systems, BEUMER Group provided them with a

complete packaging line. This includes a form fill seal system (FFS

system), the BEUMER paletpac palletising system, and the BEUMER stretch

hood high-capacity packaging system. It also includes conveying technology

for the pallets, SCADA, a warehouse control and a warehouse management

system, a guiding system for the fork-lift driver and a yard management

system. "We are in constant dialogue with the user to work out the

requirements and match them with our modular system," describes Kleigrewe.

"The result is a customised solution."

Industry 4.0 - high expectations

"The increase in networking and automation brings us on our way towards

Industry 4.0," says Kleigrewe. It creates highly interlinked system

structures with a high number of involved people, IT systems, automation

components and machines. The users can significantly improve the

organisation and control of their logistics value chain. The system,

machine and product controls must be horizontally and vertically

integrated into dynamic communications networks. This creates digital

engineering consistency through the entire logistics value chain - in

other words: it is about the intelligent networking in the supply chain.

"Making this possible in Industry 4.0 requires the development of

powerful, linked sensors and actuators. This networking, however, leads to

enormous amounts of data and metadata along the logistics value chain,"

explains Kleigrewe. Another factor is globalisation: data management is

now spread out over different locations, countries, even continents.

Horizontal and vertical interfaces can quickly become cost drivers in

factory automation. "Cloud computing offers an efficient technological

base for holding data," says the automation specialist. This service can

replace or expand existing structures. Cloud computing also allows you to

process significantly larger data volumes compared to traditional server

solutions. In addition, real-time data can be synchronised with historical

data. Uniform interfaces of the cloud services are currently in

development.

The software interface standard OPC (Unified Architecture) is useful for

making data available between all systems of a company. "It meets the most

important requirement for data communication in Industry 4.0'" explains

Kleigrewe. "This standard allows you to establish the communication

between devices, controllers and applications, regardless of the

individual driver. OPC UA can be directly embedded into devices, sensors

and controllers. Data from different, non-compatible and open standards

from different areas can also be transferred.

What will the future look like? Kleigrewe has a clear idea: "The processes

in distribution centres will run fully automatically, from order to

delivery, around the clock, seven days a week. This changes the

requirements completely, and we are already experiencing this change.